Microstructure, MAO performance, interfacial characteristics and corrosion behavior of FSW joint of Al–Mg-Sc alloy

The microstructure evolution, micro-arc oxidation (MAO) performance, and corrosion behavior of Al–Mg-Sc alloy friction stir welded (FSW) joint were investigated. The microstructure observations indicated that compared with the base metal (BM), the stirring zone (SZ) and thermo-mechanical affected zone (TMAZ) showed notable grain defects and an enormous number of high angle grain boundaries (HAGBs). Additionally, a more conspicuous presence of non-uniform recrystallized grains and HAGBs was noticed in the thickness direction within the SZ. FSW process induced the precipitation of Al₃Mg₂ (β phase) at grain boundaries in the heat-affected zone (HAZ) of joint. The microstructural changes and precipitation induced by the FSW process influenced the electrical conductivity, resulting in the differences in micro-arc discharge in various zones of the FSW joint in MAO process, which in turn affected the thickness, porosity, and corrosion resistance of MAO ceramic film. HRTEM observation suggested that a transition layer composed of nanocrystalline and amorphous Al₂O₃ with average thickness of 2–4 nm was found at the film/substrate interface. Electrochemical tests suggested that a heterogeneous structure in various regions of FSW joint resulted in varying susceptibility to localized corrosion. HAZ/TMAZ had the worst anti-corrosion performance. After MAO treatment, the anti-corrosion performance of SZ and HAZ/TMAZ in FSW joint was significantly improved, especially SZ.